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Recent Posts

  • “Monitor for Change”
  • We’re in a Tight Spot! The Importance of Straight, Unobstructed Pipe Runs in Air Flow Measurement
  • Optimization 101: Natural Gas Fired Boiler Efficiencies
  • Under Pressure: Exploring the Top 3 Industrial Benefits for Facility Pressure Control
  • 4 Key Ways to Optimize your Thermal Oxidizer

“Monitor for Change”

Posted on April 22, 2022

Earth Day 2022 / Air Monitor – ESG Statement Release

In honor of Earth Day, Air Monitor releases its Environmental Social Governance (ESG) Statement.

Socially responsible strategies are taking shape across commerce and investment firms by pledging ESG goals or initiatives. Examples of ESG targets are net-zero carbon emissions, reducing waste, alternative packaging, reduced fuel consumption, positive social change in communities, and fostering diversity in the workplace.

For our part, Air Monitor has summarized its commitment in an ESG Statement. Air Monitor believes in being a steward of nature through responsible manufacturing, material recycling, and producing eco-conscious products.

Air Monitor believes in “Monitor for Change”; as a leader in airflow measurement technology, we aim to institute ESG principles that will help maximize our impact on positive change in the world.

Visit our ESG Statement page for more information about how Air Monitor is doing their part.

We’re in a Tight Spot! The Importance of Straight, Unobstructed Pipe Runs in Air Flow Measurement

Posted on October 7, 2021

Turbulent Flow

The biggest challenge in air flow monitoring applications are obstructions causing turbulent or irregular airflow profiles in the desired straight run section. Most air flow measuring devices are adversely affected by an underdeveloped flow profile. Ideally, more straight run is added in to the length of duct or pipe where an air flow measurement device is needed to achieve the best accuracy.

Airflow Dynamics

Let’s look at the foundation of airflow dynamics in air flow measurement to understand how straight run lengths affect the flow/velocity profiles in air ducts or industrial pipes.

  • Airflow is extremely dynamic​
  • Velocity profiles can shift based on proximity to upstream/ downstream disturbance and/or the airflow velocity​
  • Accurate measurement requires multiple sensing points across measurement plane​
  • The more points of measurement, the better the measurement accuracy

The type of obstruction or elbow in the duct/pipe, the velocity, and other factors will have differing effects on the velocity profile at different distances.

90 Degree Elbow

The images below show how a duct’s airflow velocity profile is affected by a 90 degree elbow without vanes. The closer the airflow measurement is to an elbow, the more turbulent it becomes. As shown, increasing the distance from 0.5 to 2.5 diameters produces a much more uniform airflow condition.

Sweep Elbow

Of equal importance are the directional vectors of the airflow in a duct. The images below show how additional straight run downstream of a sweep elbow will develop the flow profile, so that angle of flow within a duct is improved. Many airflow technologies are susceptible to large errors with only minor angular flow components (<10 degrees).

Getting the Right Fit in a Tight Spot

Depending on the technology, the straight run requirements may be excessively long considering the installation location. What do you do when you can’t add duct or pipe lengths to accommodate air flow measuring technologies with excessively long straight run requirements? You find a technology that can accommodate the shorter straight runs by calling the Air Monitor experts.

The ACCU-flo in Action

Air Monitor manufactures airflow measuring stations, like the ACCU-flo, that have built-in flow straightening and profile conditioning technology.

This flow straightening technology is paired with a profile conditioner and air flow measuring probes that are engineered to function accurately in the specific airflow conditions in the duct.

Here are two examples of the ACCU-flo installed and accurately measuring airflow and temperature for regenerative thermal oxidizers (RTOs) with limited straight runs available:

The client – and the measurement point – were in a tight spot. Luckily, the ACCU-flo was able to straighten the flow of air in the pipe and offer a truly accurate measurement. The resulting measurements allowed the client to fine tune the airflow to improve the efficiency of the RTO for big savings.

For more information on how Air Monitor products can help in your application, contact one of our experts today!

Optimization 101: Natural Gas Fired Boiler Efficiencies

Posted on July 14, 2021

Industrial Boiler Application Optimizer

The Importance of Boilers in Industrial Processes

Industrial Boiler Application Optimizer

Boilers can be found in most industrial facilities and are used to produce steam or heat water for space and process heating. Some boilers are used for the generation of power and electricity. Some natural gas fired industrial boilers have a relatively clean airflow combustion process, but particulate-laden airflow is common and creates challenges for most flow measurement devices on the market.

How it Works

Natural gas and an airflow stream are burned to heat the inner chamber or tubes within the body of the boiler. The heat causes the temperature of the water to rise until it boils and produces steam. The combustion air and fuel feeding the burner must be tuned to the optimal air/fuel ration to improve efficiencies, minimize excess air while ensuring complete combustion, and minimize emissions. If a Flue Gas Recirculation (FGR) stream is used as a NOx reduction technique, the FGR flow should be monitored to ensure the optimal ratio of FGR to combustion airflow. The exhaust gas is then vented to atmosphere and usually must be monitored for emissions compliance.

Types of Boilers

Some common natural gas fired boilers include:

  • Large industrial boilers
  • Package boilers

Example of Annual Savings

In 2012, the US Department of Energy released a tip sheet on how to improve your boiler function and efficiency. They were able to show concrete savings for operators that successfully improve efficiencies. In their example, they calculated upwards of $200,000!

  • Annual Savings:
    • = Fuel Consumption x (1–E1/E2) x Fuel Cost
    • = 29,482 MMBtu/yr x $8.00/MMBtu
    • = $235,856

Optimization 101: Natural Gas Fired Boiler Efficiencies

Get efficient by learning these 3 combustion air flow measurement points to optimize natural gas fired boilers uncovered in the new Application Optimizer document by Air Monitor. Download your copy of the Air Monitor Application Optimizer for natural gas fired boilers to learn how to optimize your process now.

Download Application Optimizer

Under Pressure: Exploring the Top 3 Industrial Benefits for Facility Pressure Control

Posted on June 29, 2021

Space Pressure Image

Of all the things hitting your desk, why should you worry about space pressure control in your facility? We’ve done the research for you and have identified three major benefits.

Space Pressure Image

Top 3 Industrial Benefits of Facility and Space Pressure Control

#1 Quality production output/improved process control:

Where purity standards must be maintained for product quality, production output, and where improved process control is required, facility and space pressure control become important. Space pressure control can help avoid contamination of clean areas by dust, pollutants, or other undesired conditions that might impact the quality of your product.

Here’s a list of examples:

  • Manufacturing pharmaceuticals, electronics, food & beverage
  • Facilities with “clean rooms”
  • Furnace pressure control for battery recyclers (EPA regulation tied to this (40 CFR Part 63 National Emissions Standards for Hazardous Air Pollutants (NESHAP) from Secondary Lead Smelting)) for optimal process control and quality production output

#2 Cost Savings:

Without pressure control, there can be some unintended negative consequences to day-to-day functions that end up increasing facility maintenance costs. Correcting these issues help minimize system cycling and excess power use for energy savings. Let’s look at a couple examples.

First, pressure sensing devices must be used to detect pressure imbalances. Without accurate pressure sensing devices in key areas, the control system cannot function efficiently. When a pressure imbalance occurs causing exfiltration or infiltration, the control system will continue to cycle attempting to restore an unattainable balance and energy costs will soar.

Next, have you ever had trouble opening a door because of pressure imbalances? This isn’t just an inconvenience for workers trying to easily navigate the facility, sometimes with product, inventory, or other gear. It can also be a huge energy sink! Sometimes doors will not fully shut from pressure imbalances, too. This causes an air stream to form that allows heated/cooled facility air to escape the space resulting in higher energy costs. A good pressure system with accurate pressure sensors can correct these issues.

Lastly, pressure control can have some long-term benefits – like detecting leaks. The analysis of long-term aggregate pressure level data can pinpoint troublesome areas. Further inspection of the problem areas will uncover any leaks in the airflow system. Repaired leaks will create a more efficient system and save energy costs over time.

#3 Worker safety in industrial facilities:

Maintaining duct pressure levels relative to room or area pressure levels is key to worker safety. This is done by measuring pressure in duct, measuring in the space, then comparing the duct pressure to ambient air pressure. The control system adjusts – based on this data – to balance pressure accordingly. Let’s look at two examples:

  • Avoid the introduction of contaminants into work areas that jeopardize worker health and safety 
  • Space pressure control around smelting areas to protect workers in a smelting facility or foundry

Get up to date on the regulations that might be impacting your facility safety requirements.

How Does it Work?

To get a better picture, let’s look at how a theoretical example of a facility pressure control system would work.

First, the control system may measure the outdoor pressure, which changes periodically due to changes in weather. Then, the control system may monitor the pressure of spaces inside the facility. Some systems incorporate airflow measurement into this control scheme. Pressure data feeds into the control system and triggers the airflow system to open and close dampeners allowing airflow to key areas in the facility. While the air flows through the system, duct static pressure sensors feed data to the control system. Duct pressure data and ambient pressure data are compared with the pressure settings that the operator has determined are ideal atmospheric environments for the work or processes occurring in that space of the facility. In some cases, the control system may be set up to maintain a positive/negative pressure relationship between two areas to avoid contamination of production output.

Why it’s Important

Manufacturing facilities must be able to meet purity standards when producing medicines, food, beverages, electronics, or other dust- and contaminant-sensitive products. Clean rooms create a safe environment, free of contaminants, where these products can be manufactured to the high-quality standards set by the FDA or other regulatory bodies.

Industrial facilities that operate with or produce harmful pollutants like volatile organic compounds (VOCs) or hazardous air pollutants (HAPs) must be able to maintain safe working environments for their employees and ensure that these pollutants are being destroyed per regulations in air waste processing equipment like thermal oxidizers and not venting into work areas or the atmosphere.

  • Long term pressure monitoring of the waste airflow ducts compared to the ambient pressure can help detect leaks in the waste airflow feeds.
  • Keep harmful gases out of smelting and combustion processes

Although OSHA does not have specific requirements for workplace indoor air quality (IAQ), they do require employers to provide their workers with a safe workplace that does not have any known hazards that cause or are likely to cause death or serious injury. Some states, like California and New Jersey, have their own indoor air regulations.

What Can you Do to Manage Industrial Facility Pressure Challenges?

Ok. So, now that we all understand the benefits of having a pressure system and how it works, let’s discuss the challenges that commonly arise when trying to set up a pressure system and the solutions that Air Monitor offers.

Challenge 1: Design challenges

Air Monitor Solution: Full start-up services, duct traverse studies & training

Air Monitor has over 50 years’ experience providing premier airflow measurement and pressure measurement systems to industrial process markets. Our technical team ensures that your system will meet the standards that your challenging application requires.

Challenge 2: Accuracy

Air Monitor Solution: Excellent stability, repeatability, and accuracy

Air Monitor products work together with the best-in-class accuracy of our transmitters to keep your control system running smoothly.

Challenge 3: Tough industrial settings

Air Monitor Solution: Range of Offerings and Materials for Tough Environments

Air Monitor’s rugged product line can operate in corrosive, high temperature, and particulate-laden air streams.

Look at our line of products tailored to meet your facility space pressure control needs:

  • S.A.P. (Static Pressure Ports)
    • These sensors detect the pressure of an indoor space
  • S.O.A.P. (Static Outdoor Air Ports)
    • These sensors detect the pressure outdoors of a facility
  • STAT-probe
    • These sensors detect the pressure inside of a duct
  • VELTRON II Transmitter,
    • used in conjunction with our pressure sensors and airflow measurement stations can measure and help regulate space/room/area pressure
  • VEL-trol II Transmitter
    • Same great features as the VELTRON II, also includes Proportional Integral Derivative (PID) control

Feeling under pressure? Talk to an expert at Air Monitor about what you’re experiencing at your facility: Contact Us

4 Key Ways to Optimize your Thermal Oxidizer

Posted on April 26, 2021

Get Cost Savings with an Optimized Thermal Oxidizer in your Facility

Application Optimizer - thermal oxidizer - rto

The Importance of Thermal Oxidizers in Industrial Processes

Thermal Oxidizers can be found in a variety of industrial facilities and are used to process industrial waste streams before venting to the atmosphere. Specifically, they are used to remove volatile organic compounds (VOC’s) and other hazardous air pollutants (HAP’s) from process exhaust flows as required by the EPA/Clean Air Act.

How it Works

The waste gas containing the pollutants is fed into the thermal oxidizer. The combustion chamber within the thermal oxidizer must reach the targeted operating temperature to destroy the pollutants in the chamber. A burner is used to achieve the targeted temperature, so the combustion air and fuel feeding the burner must be tuned to the optimal air-fuel ratio to run efficiently. If the targeted operating temperature is maintained, the pollutants are destroyed through thermal combustion and are chemically oxidized to form exhaust gas comprised of CO2 and H2O. The exhaust gas is then vented to atmosphere.

Types of Thermal Oxidizers

Thermal oxidizer technologies include:

  • Direct fired thermal oxidizer – afterburner
  • Regenerative thermal oxidizer (RTO)
  • Direct fired with heat recovery (recuperative thermal oxidizer)
  • Flameless thermal oxidizer
  • Catalytic oxidizers (regenerative or recuperative

4 Key Ways to Optimize

Air Monitor has identified 4 key measurement points to optimize thermal oxidizers in the new Application Optimizer document. Download your copy of the Air Monitor Application Optimizer for Thermal Oxidizers to learn how to optimize your process now.

Download Application Optimizer

Air Monitor Welcomes Patrick Cool as New Director of Operations for the TASI Gas Flow Division

Posted on April 15, 2021

Patrick Cool - New Director of Operations

Air Monitor is pleased to announce that Patrick Cool is the new Director of Operations for the TASI Gas Flow division.

Patrick Cool - New Director of Operations

Patrick is the senior manager within the division responsible for Operations (manufacturing, logistics, purchasing, planning, inventory/warehouse management, facilities, manufacturing engineering, project management, environment/health & safety, and facility maintenance) for Air Monitor and the other American-based business units within the TASI Gas Flow division.  His primary focus will be on ensuring factory operational excellence and customer satisfaction for the TASI Gas Flow businesses.

Patrick first started working in manufacturing in 2012 and has held positions of management in Quality, Software Development, Information Technology and Operations since that time.  He is a graduate from the University of California – Davis with a Bachelor of Science degree in Managerial Economics.

Please join us in welcoming Patrick to the team and wishing him well in his new role.

Air Monitor is always looking for the best of the best. If you or someone you know is looking for a job in the flow industry, check out our current job openings.

Case Study: Air Monitor Airflow Measurement Systems Play Key Role in High Quality Pharmaceutical Drying Applications

Posted on March 11, 2021

Glatt Pharmaceutical Drying Equipment

Precision and Accuracy are Paramount at Glatt

Glatt Pharmaceutical Drying Equipment

Major pharmaceutical companies where solid dosage processing is required for making powders or contents of pills, tablets, and capsules have a unique need for accuracy. Glatt Air Techniques Inc. sells its equipment to such pharmaceutical companies and makers of vitamins and nutraceuticals because they are the leaders in accuracy.

“Glatt products are bought by customers to be used for the processing of very high-value products. Accuracy is key.”

Glatt must build its pharmaceutical processing equipment for extreme precision because of the high dollar value of the powders that are processed in its equipment. During the buying stage, Glatt explored several technologies. Thermal measurement could not accommodate straight pipe run requirements. Space is a premium and installations are tight on the fluid bed towers (FBTs) that Glatt manufactures. Vortex flow measurement could not meet the pressure requirements and had limited line sizes, topping out at 12” or 16”. In terms of pressure rating of the transmitter, Air Monitor’s products could withstand a high-pressure event – a critical factor. Max pressure within the unit must be able to withstand 10-12 bar rated. Airflow management is critical for ensuring high quality distribution of any ingredients and the technology used in Air Monitor products met all their high demands. The Air Monitor products at work in Glatt’s equipment are the VELTRON-II transmitter and the LO-flo/SS pitot traverse probe airflow measurement system. With a dual-range transmitter like the VELTRON-II, Glatt can measure a 25:1 turndown and the pitot static grid technology was best suited for their needs.

“The way Air Monitor products are calibrated is probably the best in the industry for precision.”

Glatt‘s equipment can be as small as a 1 kilogram processing vessel (lab-sized equipment for R&D work) up to 1,000 kilograms for industrial-sized equipment. The smallest Air Monitor equipment Glatt requires is 4”. The largest is a 24”. Air Monitor’s wide size range allowed Glatt to have the most options and the engineering support they received from Air Monitor helped tailor their specific measurement needs to their high-value product line.

“Air Monitor’s products are highly engineered and extremely reliable. They have great service and support.”

Glatt measures airflow in two places in the process: the airflow into the fluid bed tower (FBT), which is the processing unit; and upstream measuring total airflow to the process. They have trusted Air Monitor measuring equipment at these key points because accuracy and function must be spot on and Air Monitor products have met that challenge consistently for over two decades.

Download Application Guide

Maintaining Area or Room Pressurization in Manufacturing and Healthcare

Posted on July 31, 2020

Maintaining Area or Room Pressurization in Manufacturing and Healthcare

Finding and maintaining the optimal level of pressurization is a difficult balancing act. Too large of a differential and you will have problems with temperature and humidity control; perhaps also, complaints from people using the space, but when the differential is too small, processes, products, and people could be at risk.

The key to effective area pressure control is a sensitive and reliable room pressure monitor coupled with a highly accurate pressure transmitter. This equipment is best specified and installed when the room is first constructed or undergoing refurbishment; however, solutions are available for retrofitting to existing area pressurization systems. Here is what you need to know.

Positive and Negative Pressurization

Start by considering what pressurization is for. The goal is to either exclude particulates from a room, or alternatively, to keep them within a defined space or enclosure, which can be permanent or temporary.

Exclusion is achieved by maintaining pressure in the room above that in surrounding areas – a positive pressure differential. Air flowing out, from high pressure to low, prevents entry of air that contains particulates. Inclusion or retention is achieved by creating a negative pressure differential. In this scenario each time a door is opened air flows into the room, preventing particulates from leaving.

Positive Pressurization Applications

Clean rooms, as used in semiconductor manufacturing, high precision metrology and surgical environments employ positive pressurization. Typically, to ensure cleanliness, incoming air is first passed through a high efficiency filtration system.

Negative Pressurization Applications

In other situations, it is important to prevent contaminants from leaving the room. One example would be in pharma manufacturing processes that generate or release dust.

Another application is for an area, temporary or permanent, dedicated to testing and/or treatment of COVID-19 patients. It is critical to patients and staff in adjacent areas to avoid exposure to airborne pathogens like the coronavirus or other viruses and diseases that may be transmitted through contaminated air from quarantined areas.

An ASHE note on room pressurization sorts medical environments into positive and negative applications. COVID-specific recommendations are detailed under, “Negative Pressure Patient Room Options.”

Air Quality Control and its Impact on Area Pressurization

When considering applications like pharmaceutical manufacturing, it raises the importance of air quality, as well. First, humidity control impacts the manufacture of medicines. Many powder and coating processes are sensitive to moisture in the air. This shows that pressurization control requires parallel management of temperature and humidity.

Optimizing the Pressure Differential

How much difference is needed for safety and cleanliness in these situations? The answer is, not much. In general, a differential of 0.02 to 0.05 in wc (inches of water column) is enough to create the required airflow. For clean rooms, the former US Federal Standard 209E, (superseded by ISO 14644,) discussed a need for 20 ACH (air changes per hour) and a differential of at least 0.05 in wc.

Higher levels can create drafts that annoy room occupants and make it harder to open or close doors. Of greater concern, are the impacts on temperature and humidity control.

A higher differential correlates with more air changes per hour. That means a larger volume of air to heat or cool. Rooms that need a pressure differential, especially one that is positive, usually also require temperature and humidity to stay within close limits. A negative pressure pharma production area will likely also have strict humidity requirements.

Thus, the result of an excessive pressure differential is that either the airflow management system works harder to maintain those limits, or the room deviates outside them (which could have very costly consequences.) The goal then is that pressure differentials be kept as small as the control system can achieve.

Pressure Differential Measurement Technology

There are two possible approaches to measuring pressure differential. Either find the difference in static pressure inside and outside the controlled environment or measure rates of airflow in and out and extrapolate the difference.

In practice, many modern systems employ a cascading combination of the two techniques. For example, it might be appropriate to track airflow but use differential pressure monitoring to set an alarm. This helps in keeping room temperature within narrow limits. Alternatively, it could be a change in airflow that triggers an alert while differential pressure monitoring controls the air change rate.

Choosing the most appropriate method depends on application-specific details. Factors such as room size and construction, frequency of entrance/exit, and the size and arrangement of the ducting all have an impact. An airflow monitoring specialist should be asked to make a recommendation after reviewing the requirements and the proposed installation.

From the preceding discussion it should be clear that measurement accuracy is a key consideration. The ideal room pressure monitor will have fine measurement resolution, rapid sensor response, and a high sampling or measurement rate. While some users may be satisfied with an alarm when pressure goes outside set limits, most will want the room pressure monitor to interface with the airflow control system for airflow management.

For more precise pressure control, a “smart” pressure transmitter such as the VELTRON II from Air Monitor may be required. This highly accurate unit handles ultra-low differential pressures and is intended for the most demanding applications.

A feature of the VELTRON II pressure transmitter of interest is its ability to essentially “self-calibrate.” This refers to an automatic zeroing circuit that eliminates drift of the output signal drift due to thermal, electronic, or mechanical effects. It also avoids the need for initial or periodic transmitter zeroing.

Installation and Retrofit Considerations

In general, precise airflow measurements need long, straight duct runs. A feature of Air Monitor airflow measurement stations is that they provide higher accuracy over shorter lengths of straight duct than competing products. This is achieved by using multi-point averaging pitot tube technology coupled with ultra-low, highly accurate, differential pressure measurement.

Pitot technology enables measurement of true velocity pressure, (total pressure – true static pressure). Other technologies measure a reference pressure on the back or side of the probe which result in a measurement that is not true velocity pressure as derived from Bernoulli’s Equation.

Another benefit of Air Monitor equipment is the ease with which it can be applied to existing systems. Furthermore, this is feasible with minimal disruption and downtime.

Accurate and Reliable Differential Pressure Measurement Technology

The key to precise pressure differential management is accurate and reliable measurement technology. With this it is feasible to minimize air changes and associated heating, cooling, and humidification requirements while still maintaining safety and product quality as needed. To find out more about how Air Monitor can help with your area pressurization requirements, request a quote from one of our application specialists today!

Air Monitor Corporation Launches New Website Design!

Posted on June 4, 2020

To bring a seamless online experience, Air Monitor has designed a new website to unveil to their customers today!

This functional new design will help customers find products, catalogues, and other resources for their HVAC, Industrial, and Power applications much easier and faster than before. Some other new features include:

  • Rep Locator Map – A dynamic and interactive tool
  • Blog – A great new way to stay informed with recent news
  • Events – Find out when and where you can connect with Air Monitor in person

Faster, Easier Browsing for HVAC, Industrial, and Power Applications

The seamless new design uses the latest UX/UI design principles to create a great structural design:

  • Responsive – seamless mobile and desktop functionality
  • UX – customers looking for information specific to their industry will find it faster
  • UI – finding and contacting a rep for your sector on the Rep Locator Map is easier than ever

Browse now and look to experience this great new design. Contact us to tell us what you think!

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